UNIVERSITI TEKNIKAL MALAYSIA MELAKA
APPLICATION OF FINITE ELEMENT ANALYSIS (FEA) TO
ANALYZE THE EFFECT OF DIFFERENT ELECTRODE SIZE IN
MIG WELDING PROCESS
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process) with Honours.
by
MOHD HAZLAN BIN HARUN @ MAMAT
APPLICATION OF FINITE ELEMENT ANALYSIS (FEA) TO
ANALYZE THE EFFECT OF DIFFERENT ELECTRODE SIZE
IN MIG WELDING PROCESS
MOHD HAZLAN BIN HARUN @ MAMAT
DECLARATION
I hereby, declared this report entitled ‘PSM Title” is the results of my ownresearch except as cited in references.
Signature :………
Author’s Nama :………
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process) with Honours. The member of the supervisory committee is as follow :
(Signature of Supervisor)
ABSTRACT
ABSTRAK
DEDICATION
I dedicated this report for my parent, my supervisor and my friends. Without their patience, understanding, support, and most of love, the completion of this work would
ACKNOWLEDGEMENT
Alhamdullillah, praise to Allah Almighty for His blessing and His love for giving me a chance to complete this project. I wish to thank University Teknikal Malaysia Melaka because give me the good facility and environment to do this project.
My deepest gratitude goes to my Project Supervisor, En. Mohd Shukor Bin Salleh, for his technical and moral support in the initiation and successful completion of the research. His valuable crictism, fruitful discussion and continuous guidance were the source of great inspiration to me. Special thanks to all the technical staff in laboratory and workshop in FKP especially Mr. Safarizal bin Madon and Mr. Fakhrulnaim bin Ibrahim for their continuous and kind assistance.
2.4 Distortion 17 2.4.1 Physical Properties of Metal and Distortion 17
2.4.2 Type of Distortion 18
2.4.2.1 Lengthwise Shrinkage (Longitudinal Contraction) 18 2.4.2.2 Crosswise Shrinkage (Tranverse Contraction) 18
2.4.2.3 Warping (Contraction of Weld Deposite) 19
2.4.2.4 Angular Distortion 20
2.11.5.1 Solid Electrode Wire 32
2.11.5.2 Metal Core Electrode Wire 32
2.11.5.3 Flux-Cored Electrode Wires 33
3.3.1 Process Flowchart 39
3.3.1.1Workpiece Preparation 40
3.3.1.2 Welding Experiment 41
3.3.1.3 HAZ Temperature Variations Measurement 42
3.3.1.4 FEA Analysis Using MSC Patran 42
3.5.1 Welding Parameters and Voltage Setting 46
3.6 Temperature Variations Measurement 48
3.7 Cutting Welding Specimen 49
4.5.2 The relationship Between Grain Size and Heat Input 81
4.6 Hardness Test 82
5. CONCLUSION AND RECOMMENDATIONS 84
5.0 Conclusion 84
REFERENCES 86
LIST OF TABLES
2.1 Typical Compositions of Austenitic Stainless Steels 11 2.2 Typical Compositions of Ferritic Stainless Steels 12 2.3 Typical Compositions of Martensitic Stainless Steels 13 2.4 Chemical Compositions of Typical Duplex Stainless Steels 15 2.5 List Wire and Gas Combination for Semiautomatic Welding 35
2.6 Rockwell Hardness Scales 39
2.7 Typical Application of Rockwell Hardness Scales 39
3.1 Chemical Composition, (wt. %) of 310 Filler Metal Rod 44
3.2 Welding Parameter 51
4.1 Physical Properties of Stainless Steel Vary With Temperature 60
4.2 Tangent Modulus (Yield Elastic Modulus) 60
4.3 Parameter for sample 8 and 9 70
2.1 Matensite, Cementite and Ferrite Structure 17 2.2 Warpage After Welding. Dotted Line Indicate Original Position 20 2.3 Preset Plates. Dotted Lines Indicate Original Position 20
2.4 Fillet Weld Metal Shrinkage 21
2.5 Distortion in Weld 21
2.6 Heat Affected Zone 23
2.7 Schematic of the Distinct Zones in a Fusion Weld 24
2.8 Finite Element Analysis Simulation 27
2.9 The GMAW Process 29
2.10 Schematic Diagram of a Gas Metal Arc Installation 29
2.11 Schematic Metal Transfer during Welding 32
2.12 Cross section of Solid and Cored Wire 35
2.13 OTC DR 4000 Robot Welding 36
2.14 Terminology for Different Parts of the Joint 37
2.15 Types of Welds 37
2.16 Rockwell Principle 38
3.1 Filler Wire With Diameter 0.8mm, 1.0mm and 1.2mm 41
3.2 Voltage Setting of the MIG Machine 41
3.3 Stainless Steel AISI 304L 42
3.4 Research Flowchart for Austenitic Stainless Steel AISI 304L Weldments 43 3.5 V-groove shape machining process using hand grinder 44 3.6 A Rectangular Specimen of Base Material for Weld 45
3.7 Picotech Data Logger Thermocouple 46
3.8 Hand Grinder 48
3.9 OTC DR 4000 Robot Welding 49
3.12 HAZ Temperature Variation Measurements 48
3.13 Buehler Automatic Mounting Press 50
3.14 Grinder (Buehler) 51
3.15 Polisher (Buehler) 52
3.16 Image Analyzer (Buehler Omniment) 52
3.17 Rockwell Hardness Testing 57
3.18 Example of hardness test specimen 57
3.19 Amount of indentation appeared on the screen 57
4.1 The Distance Between Thermocouple 58
4.2 Dimensional Modeling Using Patran 59
2-D - 2 Dimension
3-D - 3 Dimension
EDM - Electric Discharge Machine
FE - Finite Element
FEA - Finite Element Analysis FEM - Finite Element Method
FZ - Fuzion Zone
GMAW - Gas Metal Arc Welding HAZ - Heat Affected Zone HCL - Hydrochloric Acid HNO3 - Nitric Acid
MIG - Metal Inert Gas PMZ - Partially Melted Zone SMAW - Shield Metal Arc Welding UBM - Unaffected Base Material
UTeM - Universiti Teknikal Malaysia Melaka
CHAPTER 1
INTRODUCTION
1.1 Introduction
Fusion welding processes are widely used for fabrications in many engineering applications such as aerospace, automotive and shipbuliding industries. A Metal Inert Gas (MIG) welding process consists of heating, melting and solidification of parent metals and a filler material in localized fusion zone by a transient heat source to form a joint between the parent metals. The heat source causes highly non-uniform temperature distributions across the joint and the parent metals. Therefore, the thermal expansion and contraction during heating and subsequently cooling as well as material plastic deformation at elevated temperatures result in inevitable distortions and residual stresses in the joint and the parent metals, which greatly affects the fabrication tolerance and quality (Michaleris et. al, 2000). In current industrial practice, welding processes are developed largely based on trial and error experiments incorporating with engineers knowledge and experience of previous similar designs. Simulation tools based on Finite Element (FE) method are very useful to predict welding distortions and residual stresses at the early stage of product design and welding process development (Gery et al., 2005).
Metal Inert Gas (MIG) is a semi-automatic or automatic arc welding process in which a
continuous and consumable wire electrode and a shielding gas are fed through a welding
used for thin ferrous and nonferrous metals. This process is suitable used for welding most ferrous and nonferrous metal and is used extensively in the metal fabrication industry. Because of the relatively simple nature of the process, the training of operators is easy. The process is versatile, rapid and economical and welding productivity is double that of the SMAW process. This GMAW process is currently one of the most popular welding methods, especially in industrial environments. It is because the GMAW process can be automated easily and lends itself readily to robotics and to flexible manufacturing systems (Kalpakjian and Schmid, 2006).
large change in heat input and current. A shorter arc length will cause a much greater heat input, which will make the wire electrode melt more quickly and thereby restore the original arc length. This helps operators keep the arc length consistent even when manually welding with hand-held welding guns. To achieve a similar effect, sometimes a constant current power source is used in combination with an arc voltage-controlled wire feed unit. In this case, a change in arc length makes the wire feed rate adjust in order to maintain a relatively constant arc length. In rare circumstances, a constant current power source and a constant wire feed rate unit might be coupled, especially for the welding of metals with high thermal conductivities, such as aluminum (Lincoln, 1997).
crystalline of stainless steel metal. This different zones correlate reasonably well with various transformations on appropriate phase diagrams except for where resulting structures deviates from equilibrium significantly (e.g martensite in steels). The fusion zone (or weld metal in a metal) is the portion of the weld that melted during welding, having been heated to above the temperature where melting just begins for the material being welded. The heat-affected zone HAZ is the portion of the base material that was not melted but whose properties were altered by the heat of welding through some phase transformation or reaction. The unaffected base material is the portion of the base material wherein the welding heat did not exceed the minimum required to affect it structure or properties. The weld zone encompass the fusion, partially melted and heat-affected zone, since this is the region where base material properties are effected by welding.
For this reason, the research of using the different heat input in welding the stainless steel metal was conduct to know their effect to the welding area. One of the purpose of this research is to know the properties of the weldments metal. The another purpose is to know the distortion of the welded two welded steel. The distortion in a weldment can arise when thermally induced stresses are unrestrained.
There are three fundamental dimensional changes taking place during welding can cause distortion in weld fabricated structures or weldment:
(a) Transerve shrinkage that occurs perpendicular to the weld line, (b) Longitudinal shrinkage that occurs parallel to the weld line and
(c) Any angular change that consist of rotation that occurs around the weld lines.
client's specifications prior to manufacturing or construction. Modifying an existing product or structure is utilized to qualify the product or structure for a new service condition. In case of structural failure, FEA may be used to help determine the design modifications to meet the new condition.
1.3 Problem Statement
